Engine/Transmission (1994 - 1998) Intermittent Starting Problems

[Archive]

(1/9/01) THANKS TO ALL FOR SUGGESTIONS. THE PROBLEM WAS FRIED SOLENOID CONTACTS. REPAIRED FOR $50 (INCLUDING LOCALLY PURCHASED KIT). NEEDED A 12 POINT 10 MM SOCKET TO REMOVE 3 MOUNTING BOLTS. BE SURE YOU HAVE ONE!

300 miles from home, my 94 with 178k responded with a single “click” when I tried to start it in the morning. Another turn of the key and the same thing. On the third try, it started right up.
I went to the nearest Dodge dealer and had it checked. No problems were found in the starter circuit. The batteries were checked and the all connections cleaned and a new clamp installed. No problems for a couple of weeks. Then, every now and the, the same thing. Last Saturday, on the third attempt, it stared, but I heard a weird “tinny” sound and the starter spun momentarily (not engaged). I turned the ignition switch off, BUT NOTHING HAPPENED--engine continued to run. A few more on-off twists and she quit, then started normally.
Back home, I took the truck to my home dealer, but, of course, it performed like it just rolled off the showroom floor and the dealer would (somewhat understandably) not touch it.
I am scheduled for an out of state trip next month and would like to have the problem remedied. Right now I can think of the ignition switch, or the starter relay as possible culprits. Can anyone help?

Thanks,

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94 Ram 2500 automatic. Banks Git Kit and air filter. Lock-out switch and TST shift kit. Lost kitty. 178,000 and Truckin!

[This message has been edited by Tuffcat (edited 01-09-2001). ]

[This message has been edited by Tuffcat (edited 01-09-2001). ]

[This message has been edited by Tuffcat (edited 01-09-2001). ]

[This message has been edited by Tuffcat (edited 01-09-2001). ]

[This message has been edited by Tuffcat (edited 01-09-2001). ]

 

[EMD Diesel Power]

U might want to add this to your possiblities. Starter Solenoid Contacts. Most Dodge houses just R&R the starter for the problem, but it is easily repairable. I remember seeing a couple posts awhile back on here regarding the starter solenoid. Do a search under starter, starter solenoid, etc.
However if u are pressed for time... just R&R the starter and keep the old one on the bench if u can (no core charge return) for rebuilding later. if that happens. . then u have a spare starter... #ad
#ad


Hope this helps. . #ad
#ad


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"Shadows" 96' 2500 SLT, Reg Cab, 12V, 4x4, NV4500, 4. 10s, LB, LSD, Black Exterior w/chrome rockers, Camel/Tan Interior, Towing Pkg w/ Tekonsha electric brake controller, Walker Muffler, Kitty wandered off to the woods... K&N Filter--Silencer Ring gone,AFC opened up a bit, Optima Yellow-tops, 235/85/16 Michelin LTX A/Ts Other Upgrades pending $$$$ TO THE BOMB BAY!!!!!!!

 

[ray1933]

Mine started the same thing and all the replies said new starter. That was done and it starts like new now. One question though, when you had your battries checked, did they disconect one so each one was check by its self. The first time I had mine checked when this started they said they were good, but come to find out one was bad and the other was good as they were not disconected so the reading came from the good battery. After checking them properly I now have two new ones. I figure 5 1/2 years is not bad for batteries.

 

[Joe G.]

You might search the archives. There is a repair kit for the contacts that doesn't cost much that has been mentioned in the past on these forums.

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Joe George
Eureka, CA

'95 2500 CC auto 4X4,3. 54,Combo EGT/boost guage,custom switch panel,PacBrake,TST #5,BD valve body,Automatic motorhome steps on both sides,Foldacover hard bed cover,Cummins chrome kit,Black steel grill guard,Front hitch receiver

 

[HEMI®Dart]

My starter was doing the same thing. I rebuilt the soleniod from the kit from Diesel Electric service. It was ok for a year. Got fed up with mysterious clicks and starter run on, got a good rebuilt starter from Advanced Auto for $233. 00. Lifetime guarentee. They only take a few minutes to change. Just like new now.

Lesson learned: I should have replaced the starter when it first started acting up.

[This message has been edited by HEMI®Dart (edited 01-03-2001). ]

 

[Missouri Mule]

I was having mysterious clicks a couple a weeks ago. Cleaned battery post and clamps on both batteries no more clicks.
I have recently been getting nothing(no clicks) on first to tries in morning (27-30) third turn of key is the charm.
Also in AM on driveway when starter is working fine the engine won't fire up right away. Usually takes the pedal being half way down.
Starts like it should rest of day.
I think this is being caused by Igniton switch, starter relay, or broken wire.
I also have had the starter whir several times. Tried to shut down engine with key but engine kept running. Engine would shut down by itself a few seconds after whirring sound quit. The first two times it scared the crud out of me. The third time I tried a remedy for manuals trans vehicles. It seemed to work. When you hear the whirring noise put in high gear and let clutch out a little than push back in(need to cause rocking motion). It took me one clutch in/clutch out to knock the starter gear back. Your over drive clutch will let starter gear spin to 3000 rpm if it gets stuck.
The three times the engine(whirring sound was noticed) did not shut down the truck was parked at slight incline on driveway. I think (theory) that the sprinkler systems were on and maybe the electrical connections on battery or battery solenoid got wet.

BTW when I park it on the level street at night no problems starting next morning.


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Bill Thomas
Missouri Mule - 96 Wht 4X4 ST CC,5 spd, 3. 54, 8 ft bed, 1 ft high cheater boards.
99 Freightliner bl/wht FL60 ISB-5. 9 24v,215 hp,520 tq,6 spd, 3. 59 nsr,16 ft box, 19. 5 tires,Wt/gvw 11,000/23000

 

[gibson]

It is probably one of two items. Either the solenoid as has been mentioned. You can take the contacts out. I had one good and one bad. A friend silver sautered the bad one and then used a grinder to match the good one. I have not had a problem yet. Mine acted up more when in warm, high humidty weather. Secondly, it could be the ignition and wiring in the steering column. Dodge had a recall I believe on 94, 95, and 96 models of certain trucks. It depends on what factory your truck was made. Do a search with my name, gibson, and read the replies. Someone one was kind enough to give on the specifics on which trucks. Hoep this helps.

 

[RamRunnerRob]

Tuffcat, I had the same symptoms with my '94, that you described in your post. See TDR Issue 25, pgs 18 & 19, to see how I repaired mine. If you can't find that issue, e-mail me and I will send a copy of that article to you. It took me less than an hour to fix mine. That was more than 60K miles ago.

I believe that more than half of all our starter failures can be repaired this way. The Denso starter unit is pretty well built, but those solenoid contacts are the weak point.

I talked with Keith Swearingen yesterday, and he told me that he has sold more than a hundred of these repair kits so far. NO, I DON'T receive a commission on these, just the knowledge that maybe I have helped other Ram owners keep their Cummins hummin' a little less expensively, and do it themselves. .

Keep on Truckin'...

Rob. .

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'94 2500SLT, LB, 3. 54, Automatic, TransGo Shift Kit, DunRite Convertor, TST HD Clutch Pak, TST #5 Fuel Plate, TST AFC Spring Kit, 16 sq. cm turbine housing, PacBrake, AutoLoc, EGT Gage, Mag-Hytec Diff Cover & transmission Pan, DeeZee Chrome Full Length Running Boards, Northwest Custom Rear Flaps, Vent Shades,. Pull 35' HitchHiker Premier WideBody 5th Whl (13,850+ lbs). 155,768 miles as of 1-6-01 Full Time RV'ers, Portsmouth, Ohio is "home".

[This message has been edited by RamRunnerRob (edited 01-07-2001). ]

 

[Joseph Donnelly]

The following was posted on the TST Turbodiesel list last month by Mike Hicks. Obviously your shipping charges may vary.
________________________________________

DIESEL ELECTRIC SERVICE CO. ,INC 520-836-8231 OR 1-800-836-8231 I JUST
GOT THE KIT $26. 33 + $8. 50 SHIPPING TO GA.
_________________________________________

 

[Kunze]

It's not just our starters that do the nifty one contact bad one contact good trick. The same design has been used in other applications and does the exact same thing. The contact that goes to the battery always wears at least 75% quicker. Just the nature of the beast is I guess.

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'94, 2500, 4X4, SLT, 3. 54 gears, Prime Loc, Silencer ring in the tool box, DeeZee bright tread running boards, side box boards and mud flaps. Alpine CD player. I cleared 100K mi while the board was down. Jardine Performance 4" exhaust (sounds just like a Pete, it's great) Schied Diesel put timing to *15 (by timing light), put gauges in on the A pillar (trans temp, boost, and egt) They also set my stock plate up (40 hp 150 ft/lb gain) OH, what a difference a day makes

 

[rhoads]

If the starter just runs and eng dosnt turn the starter relay (solenoid a top the starter) is'nt pulling in the bendix.
In this case, a starter solenoid is needed!
The relay only sends the signal- solenoid to engage,in turns pulls the bendix ,which in turns (at the same pull's the bendix & spins the starter/eng. ) IF your starter spins it is in theory ok,but the solenoid is not pulling in the bendix in. .
Don't know the price of the solenoid But a H--- of a lot less than $200+.
Over 700k on mine and still cranking!


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96-3500 SLT EXT. CAB AM/FM/CD-RINO LINER. D-CELERATOR EXH. BRK-RED LINE VAC. OVER HYD BRK CONTROL- AIR BAGS W/HVY DUTY AIR COMP. PUTCO S/STEEL DEEPBOARDS FRONT TO REAR. REESE 20K 5TH WHEEL & GOOSE -REESE 20K HITCH BELOW W/17K RECEVER. CLEAR COATED & SOUND DEADINGING &UNDER COATED 5 SPD/W 4:10 MCHLN'S 235/16'S UNIDEN PC76/WEATHER-WILSON 1000 MAG MOUNT ANT. 4 WHL ANTI LOC BRK SYS.

 

[BBritt]

Thank you folks for solving my problem... I have an emaculate 1994 Ram 2500 (my baby that I have pampered and all my friends want)...



I'm having EXACTLY the same problem described in this thread, occasional click, loud howling noise (starter stuck) and ignition switch will not shut her down for 30 seconds or a minute or so, until it quits the noise.



I found this TDR website by searching Google for Cummins Diesel Troubleshooting... . I just subscribed and found this solution to my problem on my second forum search.



OFF to buy a new starter... . Thanks